Semiconductor package structure for vertical mount and method

ABSTRACT

In one embodiment, a semiconductor package structure includes a plurality of upright clips having ends with mounting surfaces for vertically mounting the package to a next level of assembly. A semiconductor chip is interposed between the upright clips together with one or more spacers.

FIELD OF THE INVENTION

This invention relates generally to electronic devices, and more specifically to semiconductor packages and methods of assembly.

BACKGROUND OF THE INVENTION

The packaging of semiconductor components such as power semiconductor devices involves a number of design challenges. Such challenges include cost, heat dissipation, device protection, size, performance, and reliability among others. Examples of prior art power packages that have been developed and improved upon to address such issues include the TO-220, TO-218, CASE 77, TO-247, Dpak, D²pak, D³pak, quad flat pack no-lead (QFN), quad flat pack (QFP), small outline (SOP) packages among others.

In a typical power semiconductor package, a semiconductor chip or device is attached to a conductive lead frame having an attach paddle and conductive leads. Input/output pads on the semiconductor chip are then coupled to the leads using conductive wires. The semiconductor chip and portions of the metal lead frame are then encapsulated with an epoxy mold compound, which functions to protect the device. Portions of the conductive leads are left exposed or unencapsulated so that the packaged device may be attached to a next level of assembly such as a printed circuit board. In the prior art packages listed above, the major or main current carrying surfaces of the semiconductor device are parallel to the next level of assembly when attached thereto.

Although advances have been made in semiconductor packaging, the electronics industry still demands smaller, more cost effective, and more reliable packaged semiconductor devices. This includes packaged devices that have enhanced thermal performance, and that are adaptable to various electrical configurations.

Accordingly, a need exists for a package structure and method of manufacture that addresses these demands as well as others.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an isometric view of a semiconductor package structure in accordance with the present invention;

FIG. 2 illustrates an isometric view of a portion of the semiconductor package of FIG. 1 at an earlier step in assembly;

FIG. 3 illustrates an isometric view of a further portion of the semiconductor package of FIG. 1 after further assembly;

FIG. 4 illustrates a bottom end view of the semiconductor package structure of FIG. 1;

FIG. 5 illustrates a top end view of a plurality of semiconductor package structures of FIG. 4 in accordance with an embodiment of the present invention;

FIG. 6 illustrates a side view of the semiconductor package structure of FIG. 5;

FIG. 7 illustrates a top end view of a plurality of semiconductor package structures of FIG. 4 in accordance with another embodiment of the present invention;

FIG. 8 illustrates a side view of the semiconductor package structure of FIG. 7;

FIG. 9 illustrates a bottom end view of a semiconductor package structure in accordance with a further embodiment of the present invention;

FIG. 10 illustrates a side view of the semiconductor package structure of FIG. 9;

FIG. 11 illustrates a top end view of a plurality of semiconductor package structures of FIG. 10 in accordance with a still further embodiment of the present invention;

FIG. 12 illustrates a top end view of a plurality of semiconductor packages structures of FIG. 10 in accordance with an additional embodiment of the present invention;

FIG. 13 illustrates a side view of the semiconductor package structure of FIG. 12; and

FIGS. 14-18 illustrate the semiconductor package structures of FIGS. 9-13 in further embodiments with protective layers.

DETAILED DESCRIPTION OF THE DRAWINGS

For ease of understanding, elements in the drawing figures are not necessarily drawn to scale, and like element numbers are used where appropriate throughout the various figures to denote the same or similar elements. Although the present invention is described below in a power transistor configuration having three electrodes, those skilled in the art understand that the present invention is applicable to other semiconductor devices as well.

FIG. 1 shows an isometric view of a semiconductor package structure for vertical mount, a vertical mount power semiconductor package, a vertical mount semiconductor device, or power packaged device for upright mounting 10 in accordance with an embodiment of the present invention. In this embodiment, package structure 10 comprises a power transistor device, and includes first and second upright or upset clips, portions, or elements 11 and 13. Upright clips 11 and 13 comprise a conductive material, and provide support, protection, and current carrying electrodes for a semiconductor chip or device 14 interposed there between. By way of example, upright clip 11 provides a source or emitter contact or electrode for package structure 10, and upright clip 13 provides a drain or collector contact or electrode for package structure 10.

Package structure 10 further includes a third upright or upset clip, portion or element 16 that is interposed between upright clips 11 and 13 in this embodiment. Upright clip 16 functions as a control electrode, and is coupled to semiconductor device 14. For example, upright clip 16 functions as a gate or base contact or electrode for package structure 10. By way of example, upright clips 11, 13 and 16 comprise stamped or etched copper, a copper alloy, a copper plated iron/nickel alloy (e.g., copper plated Alloy 42), plated aluminum, plated plastic, or the like. Plated materials include copper, silver, or multi-layer plating such nickel-palladium and gold. In one embodiment and as shown in FIG. 1, upright clips 11 and 13 are slightly larger than semiconductor device 14 for added protection.

Spacers, partitions, or division members 18 and 19 are placed between upright clips 11, 13 and 16 as shown in FIG. 1. Spacers 18 and 19 may have the same shape, different shapes, the same thicknesses, or different thicknesses depending on the dimensional requirements or tolerances of package structure 10. Additionally, spacers 18 and 19 may comprise either an insulative or conductive material depending on the desired electrical characteristics of package structure 10. For example, spacer 18 may be insulative and spacer 19 may be conductive to provide a source tied to gate configuration. Alternatively, spacer 18 may be conductive and spacer 19 may be insulative to provide a drain tied to gate configuration. This provides improved design flexibility in accordance with the present invention.

When insulative, spacers 18 and/or 19 comprise, for example a ceramic, plastic, or a metal coated with an insulative material. In one embodiment, spacers 18 and 19 comprise a conductive material, but are attached to upright clips 11, 13, and 16 using an insulative material such as a non-conductive epoxy. When conductive spacers 18 and/or 19 are conductive, they comprise, for example, a material described above for upright clips 11, 13 and 16.

FIG. 2 shows an isometric view of a portion of package structure 10 at an earlier step in assembly. Specifically, semiconductor device 14 is shown with a first current carrying electrode 141 (e.g., source or emitter) and a control electrode 142 (e.g., gate or base) formed on or overlying a major surface 143 of semiconductor device 14. The major surface of semiconductor device 14 opposite that of major surface 143 is attached to upright clip 13 using a die attach layer or material such as conductive epoxy or a solder. Spacer 18 is attached to another portion of upright clip 13 using an epoxy (conductive or insulative depending on the application) or a solder.

FIG. 3 shows an isometric view of package structure 10 after upright clip 16 is attached to control electrode 142 of semiconductor device and spacer 18. In one embodiment, upright clip 16 includes a struck-up portion or member 162 for contacting control electrode 142 in a localized manner. By way of example, upright clip 16 is attached to control electrode 142 using a conductive epoxy or a solder, and is attached to spacer 18 using an epoxy (insulative or conductive) or a solder. Spacer 19 is then attached to upright clip 16 using an epoxy (insulative or conductive) or a solder depending on the device application. Next upright clip 11 is attached to current carrying electrode 141 of semiconductor device 14 using a conductive epoxy or a solder, and is attached to spacer 19 using an epoxy (insulative or conductive) or a solder to provide packaged structure 10 shown in FIG. 1.

Turning now to FIG. 4, a bottom end view of packaged structure 10 is shown. In this view, mounting ends or surfaces 111, 131, and 161 of upright clips 11, 13, and 16 respectively are shown with spacers 18 and 19 interposed there between. Mounting ends 111, 131, and 161 provide major end surfaces for mounting package structure 10 in a vertical or upright fashion to a next level of assembly in accordance with the present invention. Mounting ends 111, 131 and 161 have surface areas sufficient to attach to a next level assembly. In one embodiment, mounting ends 111, 131, and 161 have substantially flat surfaces.

FIG. 5 shows a top view of an assembly 51, which includes a plurality of package structures 10 mounted in a side by side fashion to a next level of assembly 52 (e.g., a printed circuit board). By mounting packaged structures 10 vertically, the present invention saves on horizontal board space, which allows for more components to be integrated onto the board or allows for one that is smaller. In this embodiment, packaged structures 10 are shown with adjacent upright portions 11 and adjacent upright portions 13 tied, connected, or coupled together as an example to further show the design flexibility of the present invention.

When semiconductor device 14 comprises a power MOSFET device, assembly 51 comprises a plurality of packaged power MOSFETS in a side by side source to source and drain to drain configuration. Upright clips 16 are shown in phantom in FIG. 5 since they are below upright clips 11 in this configuration, and upright clips 16 may be tied, connected, or coupled together as well in this configuration.

Plurality of package structures 10 are connected together using for example, an epoxy or a solder. In alternative embodiments, combinations of insulative and conductive epoxies or solders are used to selectively connect and/or isolate adjacent upright clips.

FIG. 6 shows a side view of assembly 51 with a package structure 10 mounted in a vertical or upright manner to printed circuit board 52. In accordance with the present invention, major surface 143 of semiconductor device 14 is perpendicular or vertical with respect to major surface 520 of printed circuit board 52. This feature serves to enhance thermal dissipation by, for example, convective cooling and further saves on horizontal space.

FIG. 7 shows a top view of an assembly 71 with a plurality of package structures 10 mounted vertically or upright on a next level of assembly (e.g., a printed circuit board) 72 in accordance with another embodiment of the present invention. In this embodiment, plurality of packaged structures 10 is in a back to back or source to source configuration. In other words, two similar current carrying electrodes are tied, connected or coupled together in this embodiment.

FIG. 8 shows a side view of assembly 71 with package structures 10 mounted in a vertical or upright manner to printed circuit board 72. In accordance with the present invention, major surfaces 143 of semiconductor devices 14 are perpendicular or vertical with respect to major surface 720 of printed circuit board 72.

Turning now to FIGS. 9-13, alternative embodiments of the present invention are described. FIG. 9 shows a bottom end view of a semiconductor package structure for vertical mount, a vertical mount power package, a vertical mount semiconductor device, or power packaged device for upright mounting 100 in accordance with another embodiment of the present invention. In this embodiment, upright clip 11 is interposed between upright clips 13 and 16. In this embodiment, mounting ends 131, 111, and 161 of upright clips 13, 11, and 16 respectively are shown. Mounting ends 131, 111, and 161 provide major end surfaces for mounting packaged structure 100 in a vertical or upright fashion to a next level of assembly in accordance with the present invention.

FIG. 10 shows a side view of an assembly 111 including a package structure 100 vertically mounted to a next level of assembly (e.g., a printed circuit board) 112. FIG. 10 further shows package structure 100 including a semiconductor device 14, which in this embodiment is rotated 180 degrees compared to semiconductor device 14 shown in FIG. 2 so that upright clip 11 is attached to electrode 141 of semiconductor device 14 towards the center portion of the package, and upright clip 16 is attached to electrode 142 of semiconductor device 14 above upright clip 11.

FIG. 11 shows a top view of assembly 111 including a plurality of package structures 100 vertically mounted to printed circuit board 112. In this embodiment, plurality of packaged structures 100 are vertically mounted in a side by side fashion so that adjacent upright clips 13, 11, and 16 of packaged structures 100 are tied, connected, or coupled together to further illustrate the design flexibility of the present invention.

FIG. 12 shows a top view of assembly 121 including a plurality of package structures 100 vertically mounted to printed circuit board 122. In this embodiment, plurality of package structures 100 are vertically mounted in a back to back fashion so that adjacent upright clips 16 of packaged structures 100 are tied, connected, or coupled together. In one embodiment, adjacent upright clips 16 are connected with an epoxy or solder layer.

FIG. 13 shows a side view of assembly 121 with package structures 100 mounted in a vertical or upright manner to printed circuit board 122. In accordance with the present invention, major surfaces 143 of semiconductor devices 14 are perpendicular or vertical with respect to major surface 1220 of printed circuit board 122. This feature serves to enhance thermal dissipation and further saves on horizontal space.

FIGS. 14-18 show the semiconductor package structures of FIGS. 9-13 in further embodiments with the addition of a protective or encapsulation layer 81 formed around portions of the package structures. By way of example, encapsulation layer 81 comprises an epoxy mold compound and is formed using conventional molding techniques. In one embodiment, the semiconductor package structures (e.g., those structures shown in FIGS. 1, and 4-13) of the present invention are formed and/or attached together as described above, and then the structures are placed into a molding apparatus to form encapsulating layer 81. In one embodiment, the encapsulated structure is then attached to a next level of assembly.

FIG. 14 is a bottom end view of package structure 100 of FIG. 9 with the addition of encapsulating layer 81 formed around portions of the structure to provide an encapsulated package structure 101. In this embodiment, encapsulating layer 81 does not cover mounting end surfaces 131, 111, or 161 so these surfaces can be attached to a next level of assembly. FIG. 15 is a side view of an assembly 151, which is similar to assembly 111 with the addition of encapsulating layer 81. In this embodiment, encapsulating layer 81 terminates as shown leaving surfaces 131, 111, and 161 exposed for attachment to printed circuit board 112.

FIG. 16 is a top view of assembly 151 showing encapsulating layer 81 formed around a plurality of package structures in accordance with a side by side configuration 106. FIG. 17 is a top view of an assembly 171 showing encapsulating layer 81 formed around a plurality of package structures in accordance with a back to back configuration 107, and FIG. 18 is a side view of assembly 171 showing encapsulating terminating to leave surfaces 131, 111, and 161 exposed for attachment to printed circuit board 122. It is understood that encapsulating layer 81 may be added to the package structures of FIGS. 1 and 4-8 as well.

Thus, it is apparent that there has been provided, in accordance with the present invention, a structure and method for forming a semiconductor package for vertical mounting to a next level of assembly. The package incorporates a plurality of upright clips and spacers to provide a structure with enhanced thermal dissipation because the package promotes heat transfer to the ambient as opposed to heat transfer through a printed circuit board as occurs in prior art designs. Additionally, the present invention provides improved design flexibility by using spacers that are conductive and/or insulative as well as upright clips that may be coupled together for example, in side by side or back to back configurations. In addition, the package saves on horizontal space when attached to a next level of assembly.

Although the invention has been described and illustrated with reference to specific embodiments thereof, it is not intended that the invention be limited to these illustrative embodiments. For example, upright clips 13 in FIGS. 7, 12, 17 may be attached together in a back to back configuration. In addition, in the multiple package embodiments of the present invention, any upright clip in one package structure may be attached to any upright clip in another package for further design flexibility (e.g., upright clip 13 in one package structure to upright clips 13, 11, or 16 in another package structure, upright clip 11 in one package to upright clips 13, 11, or 16 in another package, upright clip 16 in one package to upright clip 13, 11, or 16 in another package structure). 

1. A semiconductor package structure for vertical mounting to a next level of assembly comprising: first and second upright clips each having a substantially flat end for mounting to the next level of assembly; a semiconductor chip interposed between the first and second upright clips, the first upright clip coupled to one major surface of the semiconductor chip, and the second upright clip coupled to another major surface of the semiconductor chip; and a first spacer interposed between the first and second upright clips.
 2. The structure of claim 1 further comprising: a third upright clip interposed between the first and second upright clips and coupled one of the major surfaces of the semiconductor chip, wherein the third upright clip has a substantially flat end for mounting to the next level of assembly, and wherein the first spacer is interposed between the first and third upright clips; and a second spacer interposed between the second and third upright clips.
 3. The structure of claim 2 wherein one of the first and second spacers is conductive.
 4. The structure of claim 2, wherein the semiconductor chip comprises a power transistor, and wherein the first and second upright clips comprise current carrying electrodes and the third upright clip comprises a control electrode.
 5. The structure of claim 2, wherein the third upright clip includes a struck-up portion for contacting the semiconductor chip.
 6. The structure of claim 2, further comprising: fourth and fifth upright clips each having a substantially flat end for mounting to the next level of assembly; a second semiconductor chip interposed between the fourth and fifth upright clips, the fourth upright clip coupled to one major surface of the second semiconductor chip, and the fifth upright clip coupled to another major surface of the second semiconductor chip; a sixth upright clip interposed between the fourth and fifth upright clips and coupled to one of the major surfaces of the second semiconductor chip; a third spacer interposed between the fourth and sixth upright clips; and a fourth spacer interposed between the fifth and sixth upright clips, wherein the fourth upright clip is attached to first upright clip.
 7. The structure of claim 6, wherein the fifth upright clip is attached to the second upright clip.
 8. The structure of claim 7, wherein the third upright clip is attached to the sixth upright clip.
 9. The structure of claim 6 further comprising an encapsulating layer formed around portions of the structure.
 10. A vertical mount power semiconductor package comprising: a power semiconductor chip having first and second opposing major surfaces; a first upright clip attached to the first major surface; a second upright clip attached to the second major surface; a third upright clip attached to the second major surface; a first spacer interposed between the first and second upright clips; and a second spacer interposed between the second and third upright clips, wherein each of the first, second, and third upright clips has an end portion for mounting to a next level of assembly so that the first and second major surfaces of the power semiconductor chip are perpendicular to the next level of assembly when attached thereto.
 11. The package of claim 10 further comprising an encapsulating layer formed over portions of the package.
 12. The package of claim 10, wherein one of the first and second spacers is conductive.
 13. The package of claim 10, wherein one of the first and second spacers is insulative.
 14. The package of claim 10, wherein the power semiconductor chip comprises a MOSFET.
 15. The package of claim 10 further comprising: a second power semiconductor chip having first and second opposing major surfaces; a fourth upright clip attached to the first major surface of the second power semiconductor chip; a fifth upright clip attached to the second major surface of the second power semiconductor chip; a sixth upright clip attached to the second major surface of the second power semiconductor chip; a third spacer interposed between the forth and fifth upright clips; a fourth spacer interposed between the fifth and sixth upright clips, wherein each of the fourth, fifth, and sixth upright clips has an end portion for mounting to the next level of assembly so that the first and second major surfaces of the second power semiconductor chip are perpendicular to the next level of assembly when attached thereto, and wherein one of the first, second and third upright clips is attached to one of the fourth, fifth, and sixth upright clips.
 16. The package of claim 15 wherein the first and fourth upright clips are attached together, and wherein the second and fifth upright clips are attached together, and wherein the third and sixth upright clips are attached together.
 17. A method for forming a vertical mount semiconductor package comprising the steps of: providing a semiconductor chip having first and second opposing major surfaces; attaching a first upright clip to the first major surface; attaching a first spacer to the first upright clip; attaching a second upright clip to the second major surface and the first spacer; attaching a second spacer to the second upright clip; and attaching a third upright clip to the second major surface and the second spacer, wherein each of the first, second, and third upright clips has a substantially flat end portion for mounting to a next level assembly, and to orient the first and second major surfaces of the semiconductor chip vertically with respect to the next level of assembly.
 18. The method of claim 17 further comprising the step of forming an encapsulating layer over portions of the package.
 19. The method of claim 17, wherein the step of attaching the first spacer includes attaching a conductive spacer, and wherein the step of attaching the second spacer includes attaching an insulative spacer.
 20. The method of claim 17, further comprising the steps of: providing a second semiconductor chip having first and second opposing major surfaces; attaching a fourth upright clip to the first major surface of the second semiconductor chip; attaching a third spacer to the fourth upright clip; attaching a fifth upright clip to the second major surface of the second semiconductor chip and the third spacer; attaching a fourth spacer to the fifth upright clip; attaching a sixth upright clip to the second major surface of the second semiconductor chip and the fourth spacer, wherein the each of the fourth, fifth, and sixth upright clips has a substantially flat end portion for mounting to a next level assembly and to orient the first and second major surfaces of the second semiconductor chip vertically with respect to the next level of assembly; and attaching one of the first, second, and third upright clips to one of the fourth, fifth, and sixth upright clips. 